Light-emitting diode display panel with micro lens array

ABSTRACT

A light-emitting diode (LED) display panel includes a substrate, a driver circuit array on the substrate and including a plurality of pixel driver circuits arranged in an array, an LED array including a plurality of LED dies each being coupled to one of the pixel driver circuits, a micro lens array including a plurality of micro lenses each corresponding to and being arranged over at least one of the LED dies, and an optical spacer formed between the LED array and the micro lens array.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of application Ser. No.15/007,959, filed on Jan. 27, 2016, which is based upon and claims thebenefit of priority from Provisional Application No. 62/214,395,62/258,072, and 62/259,810, filed on Sep. 4, 2015, Nov. 20, 2015, andNov. 25, 2015, respectively, the entire contents of all of which areincorporated herein by reference.

TECHNOLOGY FIELD

The disclosure relates to a semiconductor apparatus and, moreparticularly, to a light-emitting diode (LED) display panel including asubstrate, a driver circuit including a plurality of pixel drivercircuits arranged in an array, an LED array including a plurality of LEDdies and an array of micro lenses, and methods of making the LED displaypanel.

BACKGROUND

Digital display technology has become one of the largest branches in thefield of modern electronics and optoelectronics and generates demands invarious applications where an image forming function is needed. Amongthose applications, projection-based display, which has the potential ofgenerating a large size image with low cost, is of great interest.

In a conventional projection system based on a passive imager device,such as liquid crystal display (LCD), digital mirror devices (DMD), andliquid crystal on silicon (LCOS), the passive imager device itself doesnot emit light. Specifically, the conventional projection systemprojects images by optically modulating collimated light emitted from alight source, i.e., by either transmitting, e.g., by an LCD panel, orreflecting, e.g., by a DMD panel, part of the light at the pixel level.However, the part of the light that is not transmitted or reflected islost, which reduces the efficiency of the projection system.Furthermore, to provide the collimated light, complex illuminationoptics is required to collect divergent light emitted from the lightsource. The illumination optics not only causes the system to be bulkybut also introduces additional optical loss into the system, whichfurther impacts the performance of the system. In a conventionalprojection system, typically less than 10% of the illumination lightgenerated by the light source is used to form the projection image.

Light-emitting diodes (LEDs) made of semiconductor materials can be usedin mono-color or full-color displays. In current displays that employsLEDs, the LEDs are usually used as the light source to provide the lightto be optically modulated by, e.g., the LCD or the DMD panel. That is,the light emitted by the LEDs does not form images by itself. LEDdisplays using LED panels including a plurality of LED dies as theimager devices have also been studied. In such an LED display, the LEDpanel is a self-emissive imager device, where each pixel can include oneLED die (mono-color display) or a plurality of LED dies each of whichrepresents one of primary colors (full-color display). However, thelight emitted by the LED dies is generated from spontaneous emission andis thus not directional, resulting in a large divergence angle. Thelarge divergence angle can cause various problems in an LED display. Forexample, due to the large divergence angle, the light emitted by the LEDdies can be more easily scattered and/or reflected in the LED display.The scattered/reflected light can illuminate other pixels, resulting inlight crosstalk between pixels, loss of sharpness, and loss of contrast.

SUMMARY

In accordance with the disclosure, there is provided a light-emittingdiode (LED) display panel including a substrate, a driver circuit arrayon the substrate and including a plurality of pixel driver circuitsarranged in an array, an LED array including a plurality of LED dieseach being coupled to one of the pixel driver circuits, a micro lensarray including a plurality of micro lenses each corresponding to andbeing arranged over at least one of the LED dies, and an optical spacerformed between the LED array and the micro lens array.

Also in accordance with the disclosure, there is provided a method forfabricating a light-emitting diode (LED) display panel. The methodincludes forming a transparent processing layer over an LED array havinga plurality of LED dies, and processing a portion of the transparentprocessing layer to transform the portion into a micro lens array havinga plurality of micro lenses. Each of the micro lenses corresponds to andis arranged over at least one of the LED dies.

Also in accordance with the disclosure, there is provided a method forfabricating a light-emitting diode (LED) display panel. The methodincludes providing a semiconductor epitaxial wafer having asemiconductor epitaxial layer formed on a semiconductor substrate. Thesemiconductor epitaxial layer includes a plurality of LED dies on oneside of the semiconductor epitaxial layer. The method further includesaligning and bonding the semiconductor epitaxial wafer onto a drivercircuit wafer having a plurality of driver circuits. Each of the LEDdies is bonded to one of the driver circuits. The method also includesremoving the semiconductor substrate and processing the semiconductorepitaxial layer from another side opposite to the LED dies to form aplurality of micro lenses. Each of the micro lenses corresponds to andis arranged over at least one of the LED dies.

Features and advantages consistent with the disclosure will be set forthin part in the description which follows, and in part will be obviousfrom the description, or may be learned by practice of the disclosure.Such features and advantages will be realized and attained by means ofthe elements and combinations particularly pointed out in the appendedclaims.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the invention, as claimed.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate several embodiments of theinvention and together with the description, serve to explain theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view schematically showing avertically-integrated semiconductor apparatus according to an exemplaryembodiment.

FIGS. 2A-2E schematically show a process for manufacturing thesemiconductor apparatus of FIG. 1 according to an exemplary embodiment.

FIGS. 3A-3D schematically show a process for manufacturing thesemiconductor apparatus of FIG. 1 according to another exemplaryembodiment.

FIGS. 4A and 4B schematically show a process for manufacturing thesemiconductor apparatus of FIG. 1 according to another exemplaryembodiment.

FIGS. 5A-5B schematically show a process for manufacturing thesemiconductor apparatus of FIG. 1 according to another exemplaryembodiment.

FIGS. 6A and 6B schematically show a semiconductor apparatus accordingto another exemplary embodiment.

FIGS. 7A and 7B schematically show a semiconductor apparatus accordingto another exemplary embodiment.

FIGS. 8A and 8B schematically show a semiconductor apparatus accordingto another exemplary embodiment.

FIG. 9 schematically shows a semiconductor apparatus according toanother exemplary embodiment.

FIG. 10 schematically shows an opto-electronic apparatus according to anexemplary embodiment.

FIG. 11 schematically shows an opto-electronic apparatus according toanother exemplary embodiment.

FIGS. 12A-12K schematically show a process for manufacturing theopto-electronic apparatus of FIG. 11 according to an exemplaryembodiment.

FIG. 13A schematically shows a light-emitting diode (LED) panelaccording to an exemplary embodiment.

FIG. 13B schematically shows an LED panel according to another exemplaryembodiment.

FIG. 14 schematically shows a mono-color LED projector according to anexemplary embodiment.

FIG. 15 schematically shows a multi-color LED projector according to anexemplary embodiment.

FIG. 16 schematically shows an LED display panel according to anexemplary embodiment.

FIGS. 17A-17D schematically show a process for manufacturing the LEDdisplay panel shown in FIG. 16 according to an exemplary embodiment.

FIG. 18 schematically shows a process for manufacturing the LED displaypanel of FIG. 16 according to another exemplary embodiment.

FIG. 19 schematically shows a process for manufacturing the LED displaypanel of FIG. 16 according to another exemplary embodiment.

FIG. 20 schematically shows a process for manufacturing the LED displaypanel of FIG. 16 according to another exemplary embodiment.

FIG. 21 schematically shows an LED display panel according to anotherexemplary embodiment.

FIGS. 22A and 22B schematically show LED display panels according toother exemplary embodiments.

FIG. 23 schematically shows an LED display panel according to anotherexemplary embodiment.

FIGS. 24A and 24B schematically show LED display panels according toother exemplary embodiments.

DESCRIPTION OF THE EMBODIMENTS

Hereinafter, embodiments consistent with the disclosure will bedescribed with reference to the drawings. Wherever possible, the samereference numbers will be used throughout the drawings to refer to thesame or like parts.

As discussed above, LED dies have a large divergence angle, which cancause various problems such as those discussed in the Backgroundsection. Moreover, in a projection system employing an LED array havinga plurality of LED dies as a self-emissive imager device, a projectionlens or a projection lens set is needed to project the image generatedby the LED array, and the projection lens may have a limited numericalaperture. Thus, due to the large divergence angle of the LED dies, onlya portion of the light emitted by the LED dies can be collected by theprojection lens. This reduces the brightness of the LED-based projectionsystem and/or increases the power consumption.

Embodiments consistent with the disclosure include a monolithicallyintegrated LED display panel as a self-emissive imager device, includinga substrate with an array of pixel driver circuits, an array of LED diesformed over the substrate, and an array of micro lens formed over thearray of LED dies, and methods of making the LED display panel. The LEDdisplay panel and projection systems based on the LED display panelcombine the light source, the image forming function, and the light beamcollimation function into a single monolithic device and are capable ofovercoming the drawbacks of conventional projection systems.

FIG. 1 is a cross-sectional view schematically showing an exemplaryvertically-integrated semiconductor apparatus 100 consistent withembodiments of the present disclosure. The semiconductor apparatus 100includes a driver circuit wafer 102 having a plurality of drivercircuits 104 formed therein as an array. As used herein, the term“wafer” refers to a thin portion of material that may or may not havedevice structures or other fine structure formed therein. Thesemiconductor apparatus 100 further includes a functional deviceepi-layer 105 formed over the driver circuit wafer 102. The functionaldevice epi-layer 105 includes a plurality of functional device dies 106arranged in an array. As used herein, the term “die” refers to a smallblock of semiconductor material or a small area of a portion ofsemiconductor material that includes one or more individual functionaldevices. The semiconductor apparatus 100 also includes a bonding metallayer 107 formed between the driver circuit wafer 102 and the functionaldevice epi-layer 105. The bonding metal layer 107 includes a pluralityof bonding metal pads 108 arranged in an array and isolated, bothspatially and electrically, from each other.

Consistent with the present disclosure, each of the driver circuits 104corresponds to and is horizontally aligned with one of the bonding metalpads 108. In addition, each of the functional device dies 106corresponds to and is horizontally aligned with one of the drivercircuits 104 and one of the bonding metal pads 108. That is, a drivercircuit 104 and a corresponding functional device 106 are bondedtogether through only one corresponding bonding metal pad 108. In otherwords, the driver circuits 104, the bonding metal pads 108, and thefunctional devices 106 have a one-to-one relationship.

Consistent with the present disclosure, each of the bonding metal pads108 includes one or more electrically conductive materials, such as oneor more metals or alloys, and also serves as an electrical contactbetween the corresponding driver circuit 104 and functional device die106 for transmitting electrical signals therebetween. For example, thebonding material for the bonding metal pads 108 can be tin (Sn), gold(Au), nickel (Ni), palladium (Pd), or copper (Cu), or an alloy of anytwo or more of these metals, such as Au—Sn metal alloy. Alternatively,each of the bonding metal pads 108 can include a composite layer havingmultiple sublayers each including one or more suitable bonding materialsor alloys thereof. Moreover, each of the bonding metal pads 108 can alsoinclude, on either one or each of the side facing the driver circuitwafer 102 and the side facing the functional device epi-layer 105, anadhesion layer and/or a bonding diffusion barrier layer. The adhesionlayer facilitates the adhesion between the bonding metal pad 108 and thedriver circuit wafer 102 or the corresponding functional device die 106,and the bonding diffusion barrier layer helps to prevent or reducediffusion of the bonding material(s).

In the present disclosure, the functional device dies 106 refer tosemiconductor dies that can perform certain functions. The functionaldevice dies 106 may be the same as or different from each other.According to the present disclosure, the functional device dies 106 areconfigured such that no part of a growth substrate, which is used forgrowing epitaxial layers that are used to form the functional devicedies 106, remains in the functional device dies 106.

In some embodiments, the functional device dies 106 may beopto-electronic device dies, such as light-emitting device dies orlight-absorbing device dies. The light-emitting device dies may belight-emitting diode (LED) dies. The light-emitting device dies may alsobe laser diode (LD) dies, such as edge emitting lasers (e.g.,Fabry-Perot (FP) lasers, distributed feedback (DFB) lasers, ordistributed Bragg reflector (DBR) lasers) or vertical cavity surfaceemitting lasers (VCSELs). Examples of the light-absorbing device diesinclude semiconductor photodetector dies and solar cells. If thefunctional device dies 106 are opto-electronic device dies, each of thefunctional device dies 106 includes an active region associated with acertain wavelength or a certain wavelength range, i.e., the activeregion is configured to emit or absorb light of a certain wavelength ora certain wavelength range. As noted above, the functional device dies106 can be the same as or different from each other. Correspondingly,the active regions of different functional device dies 106 can beassociated with the same or different wavelengths or wavelength ranges.

In some embodiments, if the functional device dies 106 include LED dies,each of the functional device dies 106 can include a roughened uppermostepitaxial layer. The upper surface of the uppermost epitaxial layer isroughened to improve light extraction from the LED die.

The functional device dies 106 are not limited to opto-electronicdevices, but can be other types of electrical devices. For example, thefunctional device dies 106 can be micro-electro-mechanical system (MEMS)dies, such as MEMS sensors. The functional device dies 106 can also bepower electronic device dies, such as insulated-gate bipolar transistor(IGBT) dies, Schottky barrier diode (SBD) dies, or junction barrierSchottky (JBS) rectifier dies.

Depending on the type of the functional device dies 106, the functionaldevice epi-layer 105 may be made of different types of materials. Forexample, the functional device epi-layer 105 may include elementalsemiconductors (e.g., silicon (Si) or germanium (Ge)). The functionaldevice epi-layer 105 may also include compound semiconductors, such asII-VI compound semiconductors (e.g., zinc oxide (ZnO), zinc telluride(ZnTe), and zinc sulphide (ZnS)), III-V compound semiconductors (e.g.,indium-phosphide (InP) based semiconductors such as InP, indium-galliumarsenide (InGaAs), and indium-gallium arsenide phosphide (InGaAsP),gallium-arsenide (GaAs) based semiconductors such as GaAs,aluminum-gallium arsenide (AlGaAs), and gallium arsenide antimonide(GaAsSb), or gallium-nitride (GaN) based semiconductors such as GaN,indium-gallium nitride (InGaN), and aluminum-gallium nitride (AlGaN)),or IV-IV compound semiconductors (e.g., silicon carbide (SiC) or Si—Gealloy).

In the present disclosure, the driver circuit wafer 102 is also referredto as a “driver circuit substrate” or a “carrier wafer.” The drivercircuit wafer 102 may include a semiconductor substrate, such as anamorphous semiconductor substrate, a polycrystalline semiconductorsubstrate, or a single crystalline semiconductor substrate. For example,the driver circuit wafer 102 can include a single crystalline silicon(Si) substrate or a single crystalline III-V compound semiconductorsubstrate. In some embodiments, the driver circuit wafer 102 may includeone or more dielectric layers (not shown), such as silicon dioxide(SiO₂) layers, formed over the semiconductor substrate. Wirings and/orcontacts of the driver circuits 104 may be formed in or over the one ormore dielectric layers.

Depending on the type of the functional device dies 106, the drivercircuits 104 may include different types of devices. For example, eachof the driver circuits 104 may include a single semiconductor devicesuch as a metal-oxide-semiconductor field-effect transistor (MOSFET), athin-film-transistor (TFT), a high-electron-mobility transistor (HEMT),a heterojunction bipolar transistor (HBT), a metal-semiconductor FET(MESFET), or a metal-insulator-semiconductor FET (MISFET), or anintegrated circuit including two or more of any type of the above-listeddevices.

FIG. 1 is a high-level schematic view of the semiconductor apparatus100. Each of the driver circuits 104 or the functional device dies 106is illustrated as a single block in FIG. 1, but can include multiplecomponents such as contacts and different material layers. Moreover, thesemiconductor apparatus 100 consistent with the present disclosure alsoincludes other components, such as wirings, isolation layers, and/orpassivation layers, which may be part of the driver circuit wafer 102and/or part of the functional device epi-layer 105, or may be componentsin addition to the driver circuit wafer 102, the functional deviceepi-layer 105, and the bonding metal layer 107. These other componentsare not explicitly illustrated in FIG. 1, and may also not be explicitlyillustrated in other drawings of the present disclosure. According tothe present disclosure, since the functional device dies 106 in thesemiconductor apparatus 100 do not have any part of the growth substrateremaining on top of them, the other components related to the functionaldevice dies 106, such as the wirings and passivation layers for thefunctional device dies 106, can be formed directly on the uppermostepitaxial layer in each of the functional device dies 106.

FIGS. 2A-2E schematically show an exemplary process for manufacturingthe semiconductor apparatus 100 consistent with embodiments of thepresent disclosure. As shown in FIG. 2A, a first pre-bonding metal layer202 is formed over the driver circuit wafer 102, in which the drivercircuits 104 were previously formed. The first pre-bonding metal layer202 includes a bonding material sublayer containing, for example, Sn,Au, Ni, Pd, or Cu, or an alloy thereof. The bonding material sublayermay also include a multi-layer structure having a plurality of layers ofone or more bonding materials. In some embodiments, the firstpre-bonding metal layer 202 can also include an adhesion sublayer and/ora bonding diffusion barrier sublayer formed between the bonding materialsublayer and the driver circuit wafer 102. The adhesion sublayer isconfigured to enhance the adhesion between the bonding material sublayerand the driver circuit wafer 102, while the bonding diffusion barriersublayer is configured to prevent or reduce diffusion of the bondingmaterial(s).

Referring to FIG. 2B, separate from the driver circuit wafer 102, asecond pre-bonding metal layer 204 is formed over a functional devicewafer 206. The second pre-bonding metal layer 204 includes a bondingmaterial sublayer containing, for example, Sn, Au, Ni, Pd, or Cu, or analloy thereof. The bonding material sublayer may also include amulti-layer structure having a plurality of layers of one or morebonding materials. In some embodiments, the second pre-bonding metallayer 204 can also include an adhesion sublayer and/or a bondingdiffusion barrier sublayer formed between the bonding material sublayerand the functional device wafer 206. The adhesion sublayer is configuredto enhance the adhesion between the bonding material sublayer and thefunctional device wafer 206, while the bonding diffusion barriersublayer is configured to prevent or reduce diffusion of the bondingmaterial(s). In the present disclosure, the functional device wafer 206is also referred to as an “epi wafer.” The functional device wafer 206includes a functional device epi-structure layer 208, which is alsoreferred to as an “epi-structure layer,” epitaxially grown on a growthsubstrate 210. Depending on the type of the functional device dies 106to be formed as discussed above, the epi-structure layer 208 can includedifferent epitaxial structures that are suitable for forming the finalfunctional device dies 106. For example, the epi-structure layer 208 caninclude an opto-electronic device epi-structure layer, such as an LEDepi-structure layer, a VCSEL epi-structure layer, or a photodetectorepi-structure layer. As another example, the epi-structure layer 208 caninclude a MEMS epi-structure layer, such as a MEMS sensor epi-structurelayer.

The growth substrate 210 can be any substrate that is suitable for theepitaxial growth of the epi-structure layer 208, and is separatelyprovided. For example, if the epi-structure layer 208 includes aGaN-based material, the growth substrate 210 can be a sapphiresubstrate, such as a patterned sapphire substrate, or can be a SiCsubstrate. As another example, if the epi-structure layer 208 includesan InP-based material, the growth substrate 210 can be an InP substrate.As a further example, if the epi-structure layer 208 includes aGaAs-based material, the growth substrate 210 can be a GaAs substrate.

Referring to FIG. 2C, the functional device wafer 206 having the secondpre-bonding metal layer 204 formed thereon is transferred over andaligned with the driver circuit wafer 102 having the first pre-bondingmetal layer 202 formed thereon (shown in FIG. 2A), with the secondpre-bonding metal layer 204 facing the first pre-bonding metal layer202. The functional device wafer 206 is brought into contact with thedriver circuit wafer 102, such that the second pre-bonding metal layer204 contacts and is pressed against the first pre-bonding metal layer202. A bonding process is conducted to bond the first and secondpre-bonding metal layers 202 and 204 to each other to form anunpatterned bonding metal layer 212. In some embodiments, the bondingprocess includes heating at an elevated temperature such that at least aportion of the first pre-bonding metal layer 202 and at least a portionof the second pre-bonding metal layer 204 melt and the first and secondpre-bonding metal layers 202 and 204 are welded to each other. Thetemperature at which the bonding process is conducted depends on thebonding material(s) used, and can, for example, range from about 230° C.to higher than 350° C. when Au—Sn alloy is used as the bonding material.Other bonding techniques can also be applied as long as they can bondthe first and second pre-bonding metal layers 202 and 204 together.

After the first and second pre-bonding metal layers 202 and 204 arebonded together to form the unpatterned bonding metal layer 212, thegrowth substrate 210 is removed to expose the epi-structure layer 208,as shown in FIG. 2D. The growth substrate 210 can be removed using anysuitable physical or chemical substrate removing technique, such aslaser lift-off, chemical-mechanical polishing (CMP), or wet etching.

After the growth substrate 210 is removed, the remaining partsconstitute another exemplary semiconductor apparatus 200 consistent withembodiments of the present disclosure. That is, the semiconductorapparatus 200 is an intermediate product formed during the process offorming the semiconductor apparatus 100. The semiconductor apparatus 200includes the driver circuit wafer 102 having the plurality of drivercircuits 104 arranged in an array, the unpatterned bonding metal layer212 formed over the driver circuit wafer 102, and the epi-structurelayer 208 formed over the unpatterned bonding metal layer 212. Inparticular, like the semiconductor apparatus 100, the semiconductorapparatus 200 does not include the growth substrate 210, and thereforethe epi-structure layer 208 is exposed to the environment. Differentfrom the semiconductor apparatus 100, the semiconductor apparatus 200has a horizontally continuous unpatterned bonding metal layer 212 and ahorizontally continuous epi-structure layer 208.

Consistent with the present disclosure, after the growth substrate 210is removed, the epi-structure layer 208 and the unpatterned bondingmetal layer 212 can be patterned, for example, using a photo-lithographymethod, to form functional device mesas 214 and the bonding metal pads108, respectively, as shown in FIG. 2E. Details of this patterningprocess are omitted here. In some embodiments, the functional devicemesas 214 may be the functional device dies 106, so that thesemiconductor apparatus shown in FIG. 2E, which results from theexemplary process described above, is equivalent to the semiconductorapparatus 100 shown in FIG. 1. In some embodiments, further processingmay be performed to form the functional device dies 106 from thefunctional device mesas 214, so as to form the semiconductor apparatus100 shown in FIG. 1. Moreover, following the patterning process, otherprocesses can be conducted to, for example, form wirings, insulationlayers, and/or passivation layers, or to roughen upper surfaces of thefunctional device dies 106 to improve light extraction in the case of,e.g., LED dies. Descriptions of such processes are also omitted here.

FIGS. 3A-3D schematically show another exemplary process formanufacturing the semiconductor apparatus 100 consistent withembodiments of the present disclosure. In this exemplary process, thesteps of forming the first and second pre-bonding metal layers 202 and204 over the driver circuit wafer 102 and the functional device wafer206, respectively, are similar to those described above in connectionwith FIGS. 2A and 2B. Therefore, these two steps are not illustratedagain in FIGS. 3A-3D, and the descriptions thereof are omitted.

Referring to FIG. 3A, the first pre-bonding metal layer 202 is patternedto form first pre-bonding metal pads 302. The first pre-bonding metalpads 302 are arranged in an array. Each of the first pre-bonding metalpads 302 corresponds to and is electrically coupled to one of the drivercircuits 104. In some embodiments, one first pre-bonding metal pad 302corresponds to only one driver circuit 104.

According to the present disclosure, the first pre-bonding metal layer202 can be patterned using any suitable patterning method. For example,the first pre-bonding metal layer 202 can be patterned using aphoto-lithography method, during which the first pre-bonding metal layer202 is etched to remove portions thereof, so as to form the firstpre-bonding metal pads 302. Alternatively, the first pre-bonding metallayer 202 can be patterned using a lift-off method. To pattern the firstpre-bonding metal layer 202 by the lift-off method, a layer of amaterial suitable for lift-off (not shown in the drawings), such as aphotoresist layer, can be formed over the driver circuit wafer 102 andbe patterned before the first pre-bonding metal layer 202 is formed. Inthis scenario, the first pre-bonding metal layer 202 is formed over thepatterned lift-off material layer. The patterned lift-off material layeris then removed along with the portions of the first pre-bonding metallayer 202 that are formed directly on the lift-off material layer. Theremaining portions of the first pre-bonding metal layer 202 form thefirst pre-bonding metal pads 302.

Referring to FIG. 3B, the second pre-bonding metal layer 204 ispatterned to form second pre-bonding metal pads 304 that are arranged inan array. Each of the second pre-bonding metal pads 304 corresponds toone of the first pre-bonding metal pads 302, and also corresponds to oneof the functional device dies 106 to be formed. Consistent with thepresent disclosure, the second pre-bonding metal layer 204 can bepatterned using a method similar to that used to pattern the firstpre-bonding metal layer 202, e.g., the second pre-bonding metal layer204 can be patterned by etching or lift-off.

After the first and second pre-bonding metal layers 202 and 204 arepatterned, the functional device wafer 206 is transferred over andaligned with the driver circuit wafer 102, with the second pre-bondingmetal pads 304 facing corresponding ones of the first pre-bonding metalpads 302, as shown in FIG. 3C. Each of the second pre-bonding metal pads304 is aligned with one of the first pre-bonding metal pads 302. Thefunctional device wafer 206 is brought into contact with the drivercircuit wafer 102, such that the second pre-bonding metal pads 304contact and are pressed against their corresponding first pre-bondingmetal pads 302. A bonding process similar to that described with respectto FIG. 2C is conducted to bond the second pre-bonding metal pads 304with the first pre-bonding metal pads 302 to form the bonding metal pads108.

After the first and second pre-bonding metal pads 302 and 304 are bondedtogether to form the bonding metal layer 107 having the bonding metalpads 108, the growth substrate 210 is removed to expose theepi-structure layer 208, as shown in FIG. 3D.

After the growth substrate 210 is removed, the remaining partsconstitute another exemplary semiconductor apparatus 300 consistent withembodiments of the present disclosure. That is, the semiconductorapparatus 300 is another intermediate product formed during the processof forming the semiconductor apparatus 100. The semiconductor apparatus300 includes the driver circuit wafer 102 having the plurality of drivercircuits 104 arranged in an array, the bonding metal layer 107 formedover the driver circuit wafer 102 and having the bonding metal pads 108arranged in an array, and the epi-structure layer 208 formed over thebonding metal layer 107. In particular, like the semiconductor apparatus100, the semiconductor apparatus 300 does not include the growthsubstrate 210, and therefore the epi-structure layer 208 is exposed tothe environment. Different from the semiconductor apparatus 100, thesemiconductor apparatus 300 has a horizontally continuous epi-structurelayer 208.

Consistent with the present disclosure, after the growth substrate 210is removed, the epi-structure layer 208 can be patterned, for example,using a photo-lithography method, to form the functional device mesas214, resulting in a semiconductor apparatus similar to that shown inFIG. 2E, which is thus not shown again. Details of patterning theepi-structure layer 208 are omitted here.

FIGS. 4A and 4B schematically show another exemplary process formanufacturing the semiconductor apparatus 100 consistent withembodiments of the present disclosure. In this exemplary process, thesteps of forming the first and second pre-bonding metal layers 202 and204, and the steps of patterning the first and second pre-bonding metallayers 202 and 204 to form the first and second pre-bonding metal pads302 and 304 are similar to those described above in connection withFIGS. 2A, 2B, 3A, and 3B. Therefore, these steps are not illustratedagain in FIGS. 4A and 4B, and the descriptions thereof are omitted.

Referring to FIG. 4A, the epi-structure layer 208 is patterned to formthe functional device mesas 214. For example, the epi-structure layer208 can be patterned by etching using the second pre-bonding metal pads304 as masks. As another example, the epi-structure layer 208 can bepatterned by a separate photolithography process, which includes, e.g.,forming a photoresist layer over the epi-structure layer 208 and thesecond pre-bonding metal pads 304, patterning the photoresist layer toremove portions of the photoresist layer with remaining portions overthe second pre-bonding metal pads 304, and then etching theepi-structure layer 208 using the remaining portions of the photoresistlayer as masks. Each of the remaining portions of the photoresist layermay have a larger area than the corresponding second pre-bonding metalpad 304, and thus each of the functional device mesas 214 formed by theabove second exemplary process may have a larger area than thecorresponding second pre-bonding metal pad 304, although the larger areais not explicitly illustrated in FIG. 4A.

Then, as shown in FIG. 4B, the functional device wafer 206 is bondedwith the driver circuit wafer 102. A bonding process similar to thatdescribed above in connection with FIG. 3C is conducted to bond thefunctional device wafer 206 and the driver circuit wafer 102.

After the functional device wafer 206 and the driver circuit wafer 102are bonded together, the growth substrate 210 is removed to expose thefunctional device mesas 214, resulting in a semiconductor apparatussimilar to that shown in FIG. 2E, which is thus not shown again.

In the exemplary process described above in connection with FIGS. 4A and4B, the second pre-bonding metal layer 204 is first formed and patternedto form the second pre-bonding metal pads, and the epi-structure layer208 is patterned thereafter. In some embodiments, the epi-structurelayer 208 can be patterned before the second pre-bonding metal layer 204is formed over the functional device wafer 206. This exemplary processis described below in connection with FIGS. 5A and 5B.

In this exemplary process, the steps of forming and patterning the firstpre-bonding metal layer 202 are similar to those described above inconnection with FIGS. 2A and 3A. Therefore, these steps are notillustrated again in FIGS. 5A and 5B, and the descriptions thereof areomitted.

Referring to FIG. 5A, the epi-structure layer 208 is patterned, forexample, using a photolithography method, to form the functional devicemesas 214. Then, as shown in FIG. 5B, the second pre-bonding metal pads304 are formed over the functional device mesas 214. For example,forming the second pre-bonding metal pads 304 can include firstdepositing the pre-bonding metal layer 204 (not shown in FIG. 5B) andthen patterning the pre-bonding metal layer 204 to form the secondpre-bonding metal pads 304. The subsequent processing steps of thisexemplary process are similar to those described above in connectionwith FIGS. 4B and 4C, and thus are not illustrated and descriptionsthereof are omitted.

In the exemplary process described above in connection with FIGS. 2A-2E,both the first and second pre-bonding metal layers 202 and 204 arepatterned after the driver circuit wafer 102 and the functional devicewafer 206 are bonded together, while in the exemplary processesdescribed above in connection with FIGS. 3A-5B, both the first andsecond pre-bonding metal layers 202 and 204 are patterned before thedriver circuit wafer 102 and the functional device wafer 206 are bondedtogether. In other embodiments, either one of the first pre-bondingmetal layer 202 or the second pre-bonding metal layer 204 can bepatterned before the bonding process and the other one can be patternedafter the bonding process.

In the exemplary processes described above in connection with FIGS.3A-5B, the first and second pre-bonding metal pads 302 and 304 areformed before the bonding process. The first pre-bonding metal pads 302are physically and electrically separated from each other. Similarly,the second pre-bonding metal pads 304 are physically and electricallyseparated from each other. However, during the bonding process, portionsof the first and second pre-bonding metal pads 302 and 304 may melt and,under the pressure exerted during the bonding process, the melt metalfrom the first and/or second pre-bonding metal pads 302, 304 may flowalong the surface of the driver circuit wafer 102 and reach neighboringfirst and/or second pre-bonding metal pads 302, 304, causing a shortcircuit in the resulting semiconductor apparatus. To avoid this issue,structures preventing the melt metal from reaching neighboring firstand/or second pre-bonding metal pads 302, 304 can be formed in thesemiconductor apparatus. FIGS. 6A and 6B schematically show an exemplarysemiconductor apparatus 600 having such structures consistent withembodiments of the present disclosure.

FIG. 6A is a cross-sectional view schematically showing thesemiconductor apparatus 600, which is similar to the semiconductorapparatus 100, except that the semiconductor apparatus 600 furtherincludes a dielectric isolation layer 602 arranged between the drivercircuit wafer 102 and the functional device epi-layer 105. Thedielectric isolation layer 602 includes first protrusion structures 604and second protrusion structures 606 surrounding the first protrusionstructures 604. As shown in FIG. 6A, each of the first protrusionstructures 604 is formed over one of the driver circuits 104, and eachof the bonding metal pads 108 is formed over one of the first protrusionstructures 604. That is, each of the first protrusion structures 604“holds” one bonding metal pad 108, and thus the first protrusionstructures 604 are also referred to in this disclosure as “bonding metalpad plateaus” or “solder pad plateaus.”

FIG. 6B is a plan view of the semiconductor apparatus 600, showing thesecond protrusion structures 606 surrounding each of the firstprotrusion structures 604 and separating neighboring first protrusionstructures 604 from each other. As shown in FIGS. 6A and 6B, each of thefirst protrusion structures 604 and the corresponding neighboring secondprotrusion structures 606 define a recess 608 surrounding the firstprotrusion structure 604. During the bonding process, if melt bondingmetal outflows from the first protrusion structures 604, it is containedin the recesses 608 and confined by the second protrusion structures606, and does not reach neighboring bonding metal pads 108. Thus, therecesses 608 are also referred to in this disclosure as “bonding metalreservoirs” or “solder reservoirs,” and the second protrusion structures606 are also referred to as “bonding metal confinement dams” or “solderconfinement dams.”

Referring again to FIG. 6A, each of the first protrusion structures 604includes a through hole 610 formed between the upper surface and thelower surface of that first protrusion structure 604. At least a portionof the corresponding bonding metal pad 108 is formed in the through hole610, forming an electrical path to the corresponding driver circuit 104located beneath the first protrusion structure 604.

Consistent with the present disclosure, the dielectric isolation layer602 can also be included in the semiconductor apparatus 300, in a mannersimilar to that shown in FIGS. 6A and 6B and described above.

As described above, the functional device dies 106 are spatiallyseparated from each other. In some embodiments, an isolation layer maybe formed between the functional device dies 106. FIGS. 7A and 7Bschematically show another exemplary semiconductor apparatus 700consistent with embodiments of the present disclosure. The semiconductorapparatus 700 is similar to the semiconductor apparatus 100, except thatthe semiconductor apparatus 700 further includes an isolation layer 702formed between the functional device dies 106. FIG. 7A is across-sectional view schematically showing the semiconductor apparatus700. In the example shown in FIG. 7A, the top surface of the isolationlayer 702 is flat or approximately flat, and is flush or approximatelyflush with top surfaces of the functional device dies 106. However, theisolation layer 702 can be higher or lower than the functional devicedies 106. Consistent with the present disclosure, the isolation layer702 can be formed of, for example, a dielectric material to improve theelectrical isolation between neighboring functional device dies 106.

As noted above, the functional device dies 106 can be opto-electronicdevice dies that can emit or absorb light of a certain wavelength. Thespatial separation among the opto-electronic device dies can ensure goodoptical isolation between neighboring opto-electronic device dies. Suchan optical isolation can, for example, reduce cross-talk between theneighboring opto-electronic device dies. The optical isolation can befurther improved by choosing a suitable material for the isolation layer702 in the semiconductor apparatus 700. That is, the isolation layer 702can be formed of a material that further reduces light transmissionbetween neighboring opto-electronic device dies. For example, thematerial can be a light absorptive material that can absorb light havinga wavelength associated with an opto-electronic device die, such as anLED die. In the present disclosure, a wavelength or a wavelength rangeassociated with a die or a layer refers to a wavelength or a wavelengthrange of light emitted or absorbed by the die or the layer. Theabsorptive material can be a material having a lower transparency thanair. In some embodiments, the isolation layer 702 is formed of amaterial that is non-transparent to light having a wavelength associatedwith the opto-electronic device dies. For example, if theopto-electronic device dies include LED dies that emit blue light, amaterial non-transparent to blue light can be chosen to form theisolation layer 702. Alternatively, the isolation layer 702 can includea reflective material that can reflect light having a wavelengthassociated with an opto-electronic device die, such as an LED die. Forexample, the reflective material may reflect the light emitted by an LEDdie back to that LED die. The reduced-transparency (absorptive) materialor the reflective material increases the optical confinement ofindividual opto-electronic device dies and enhances the opticalisolation.

In some embodiments, in the scenario that the functional device dies 106include opto-electronic device dies, the isolation layer 702 does notneed to completely fill in the space between neighboring opto-electronicdevice dies, but can be formed as conformal layers on the sidewalls ofthe opto-electronic device dies, especially if the isolation layer 702is formed of a reflective material.

In some embodiments, as shown in FIG. 7A, the semiconductor apparatus700 further includes a plurality of ground pads 704, also referred to as“ground electrodes,” formed in a dielectric layer (not shown) in thedriver circuit wafer 102. Each of the ground pads 704 is associated withone of the driver circuits 104 and provides a ground level to theassociated driver circuit 104. The ground pads 704 are electricallycoupled to each other and to a common ground (not shown) of thesemiconductor apparatus 700.

As shown in FIG. 7A, the semiconductor apparatus 700 further includes aplurality of metal wirings 706 formed over the isolation layer 702. Eachof the metal wirings 706 contacts a portion of the top surface of acorresponding functional device die 106, and is electrically coupled tothe corresponding functional device die 106. For example, each of themetal wirings 706 can be in direct contact with the uppermost epitaxiallayer in the corresponding functional device die 106. Moreover, each ofthe metal wirings 706 includes a plug portion 708 formed in a wiringthrough hole 710 formed in the isolation layer 702. Each of the metalwirings 706 contacts and is electrically coupled to a correspondingground pad 704 via the plug portion 708 of the metal wiring 706. Thus,the metal wirings 706 form a cross-connected metal layer.

FIG. 7B is a plan view of the semiconductor apparatus 700, schematicallyshowing the wiring of the semiconductor apparatus 700 in a functionaldevice area 711 containing the functional device dies 106. Moreover, asshown in FIG. 7B, the semiconductor apparatus 700 further includes adata interface 712 for receiving and/or outputting data, e.g., inputdata used to control the operations of the functional device dies 106 oroutput data generated by the functional device dies 106. Thesemiconductor apparatus 700 also includes a control portion 714 coupledbetween the data interface 712 and the functional device area 711. Thecontrol portion 712 may include, for example, one or more shiftregisters, one or more digital-analog converters (DACs), and/or one ormore scan controllers.

In the semiconductor apparatus 700, the metal wirings 706 contact andare electrically coupled to the ground pads 704, each of which isassociated with one of the driver circuits 104. FIGS. 8A and 8B arecross-sectional and plan views, respectively, of another exemplarysemiconductor apparatus 800 consistent with embodiments of the presentdisclosure. As shown in FIGS. 8A and 8B, the semiconductor apparatus 800includes a continuous wiring layer 802 formed over the isolation layer702. The wiring layer 802 contacts and is electrically coupled to eachof the functional device dies 106. For example, the wiring layer 802 canbe in direct contact with the uppermost epitaxial layer in each of thefunctional device dies 106. The wiring layer 802 is further electricallycoupled to ground pads 804 formed in a peripheral region surrounding thefunctional device area 711, as shown in FIG. 8B.

In some embodiments, a semiconductor apparatus consistent with thepresent disclosure does not include the above-described isolation layer702, but instead has a conformal passivation layer formed all over thesemiconductor apparatus. FIG. 9 is a cross-sectional view schematicallyshowing such an exemplary semiconductor apparatus 900. The semiconductorapparatus 900 is similar to the semiconductor apparatus 100, except thatthe semiconductor apparatus 900 further includes a passivation layer902. As shown in FIG. 9, the passivation layer 902 is conformally formedover the functional device dies 106, the bonding metal pads 108, and theexposed area of the driver circuit wafer 102. For example, thepassivation layer 902 can be in direct contact with the uppermostepitaxial layer in each of the functional device dies 106.

In some embodiments, as shown in FIG. 9, the semiconductor apparatus900, like the semiconductor apparatus 700, also includes the ground pads704 formed in a dielectric layer (not shown) in the driver circuit wafer102. Functional device contact openings 904 and ground contact openings906 are formed through the passivation layer 902 in areas over thefunctional device dies 106 and the ground pads 704, respectively. Metalwirings 908 are formed over the passivation layer 902, each of which iselectrically coupled to the upper surface of one of the functionaldevice dies 106 and the corresponding ground pad 704.

In the above-described drawings, the functional device epi-layer 105,the bonding metal layer 107, and the driver circuit wafer 102 are shownone over another. In some embodiments, the semiconductor apparatusconsistent with the present disclosure may further include one or moreelectrode layers. For example, the semiconductor apparatus may include adevice side electrode layer formed between the functional deviceepi-layer 105 and the bonding metal layer 107. The device side electrodelayer can be formed of one or more conducting materials, and include aplurality of device side electrodes. Each of the device side electrodescorresponds to one of the functional device dies 106 and one of thebonding metal pads 108, and provides an electrical path between thecorresponding functional device die 106 and bonding metal pad 108.

The material(s) forming the device side electrode layer may be differentfor different types of functional device dies 106. For example, if thefunctional device dies 106 include LED dies, the device side electrodelayer can include a reflecting layer formed over the bonding metal layer107 and a transparent conducting material layer formed over thereflecting layer. The reflecting layer reflects the light generated bythe LED dies, increasing the efficiency of the LED dies, and may includea reflecting material, such as Sn, aluminum (Al), silver (Ag), rhodium(Rd), copper (Cu), or Au, or a reflecting structure, such as DBR.

In some embodiments, the semiconductor apparatus may additionally oralternatively include a driver side electrode layer formed between thebonding metal layer 107 and the driver circuit wafer 102. The driverside electrode layer can be formed of one or more conducting materials,and include a plurality of driver side electrodes. Each of the driverside electrodes corresponds to one of the bonding metal pads 108 and oneof the driver circuits 104, and provides an electrical path between thecorresponding bonding metal pad 108 and driver circuit 104. Consistentwith the present disclosure, the driver side electrode layer can beformed on the driver circuit wafer 102, or at least partially in adielectric layer formed over or in the driver circuit wafer 102.

As discussed above, the semiconductor apparatus consistent with thepresent disclosure can include opto-electronic device dies and thus bean opto-electronic apparatus. The opto-electronic device dies in thesame opto-electronic apparatus can have a similar structure and areassociated with light having a similar wavelength or a similarwavelength range. In some embodiments, additional optical elementshaving different associated wavelengths or wavelength ranges may beformed in the opto-electronic apparatus for different opto-electronicdevice dies.

FIG. 10 is a cross-sectional view schematically showing an exemplaryopto-electronic apparatus 1000 consistent with embodiments of thepresent disclosure. The opto-electronic apparatus 1000 includes thedriver circuit wafer 102 having the driver circuits 104, the bondingmetal layer 107 formed over the driver circuit wafer 102 and having thebonding metal pads 108, and an opto-electronic epi-layer 1005 formedover the bonding metal layer 107 and having a plurality ofopto-electronic device dies 1006. The opto-electronic apparatus 1000further includes a first optical element 1010 a, a second opticalelement 1010 b, and a third optical element 1010 c. As shown in FIG. 10,each of the first, second, and third optical elements 1010 a, 1010 b,and 1010 c is formed over one of the opto-electronic device dies 1006.In other embodiments, each of the first, second, and third opticalelements 1010 a, 1010 b, and 1010 c may be formed over one or more ofthe opto-electronic device dies 1006. The first, second, and thirdoptical elements 1010 a, 1010 b, and 1010 c are associated with a firstwavelength or a first wavelength range, a second wavelength or a secondwavelength range, and a third wavelength or a third wavelength range,respectively, which may be different from each other. In the exampleshown in FIG. 10, the first, second, and third optical elements 1010 a,1010 b, and 1010 c are formed to cover all exposed surfaces of thecorresponding opto-electronic device dies 1006. In other embodiments,the first, second, and third optical elements 1010 a, 1010 b, and 1010 ccan be formed, for example, to only over the upper surfaces of thecorresponding opto-electronic device dies 1006.

Depending on the type of the opto-electronic device dies 1006, thefirst, second, and third optical elements 1010 a, 1010 b, and 1010 c canbe different types of optical elements. For example, the opto-electronicdevice dies 1006 are LED dies, such as GaN-based ultra-violet (UV) LEDdies. In this scenario, the first, second, and third optical elements1010 a, 1010 b, and 1010 c can be phosphor layers containing differenttypes of phosphors. For example, the first optical element 1010 a cancontain blue phosphors, the second optical element 1010 b can containgreen phosphors, and the third optical element 1010 c can contain redphosphors. As such, UV light emitted by the LED dies can be convertedinto different colors. Such an opto-electronic apparatus can be used,for example, as a full-color display panel or as a white-lightillumination panel.

As another example, the opto-electronic device dies 1006 arephotodetector dies, such as Si-based photodetector dies or III-Vmaterial-based photodetector dies. In this scenario, the first, second,and third optical elements 1010 a, 1010 b, and 1010 c can be filterlayers that allow light of different wavelengths or different wavelengthranges to pass through. For example, the first optical element 1010 acan be a filter layer that allows blue light to pass through, the secondoptical element 1010 b can be a filter layer that allows green light topass through, and the third optical element 1010 c can be a filter layerthat allows red light to pass through. Such an opto-electronic apparatuscan be used, for example, as a full-color sensor used in a digitalcamera.

As an alternative to the examples described above, the opto-electronicdevice dies themselves can be configured in such a manner that they areassociated with different wavelengths or different wavelength ranges.FIG. 11 is a cross-sectional view schematically showing anotherexemplary opto-electronic apparatus 1100 consistent with embodiments ofthe present disclosure. The opto-electronic apparatus 1100 includes thedriver circuit wafer 102 having the driver circuits 104, the bondingmetal layer 107 formed over the driver circuit wafer 102 and having thebonding metal pads 108, and an opto-electronic epi-layer 1105 formedover the bonding metal layer 107 and having a plurality ofopto-electronic device dies 1106. The opto-electronic device dies 1106include a first opto-electronic device die 1106 a associated with afirst wavelength or a first wavelength range, a second opto-electronicdevice die 1106 b associated with a second wavelength or a secondwavelength range, and a third opto-electronic device die 1106 cassociated with a third wavelength or a third wavelength range. Thefirst, second, and third wavelengths, or the first, second, and thirdwavelength ranges, can be different from each other.

FIG. 11 only shows one first opto-electronic device die 1106 a, onesecond opto-electronic device die 1106 b, and one third opto-electronicdevice die 1106 c. However, consistent with the present disclosure, theopto-electronic apparatus 1100 can have more than one firstopto-electronic device die 1106 a, more than one second opto-electronicdevice die 1106 b, and/or more than one third opto-electronic device die1106 c.

In some embodiments, the opto-electronic device dies 1106 a, 1106 b, and1106 c are light-emitting dies such as LED dies that emit light ofdifferent wavelengths or different wavelength ranges. For example, thefirst, second, and third opto-electronic device dies 1106 a, 1106 b, and1106 c can be red, green, and blue LED dies, respectively, or be red,blue, and green LED dies, respectively, or be green, red, and blue LEDdies, respectively, or be green, blue, and red LED dies, respectively,or be blue, red, and green LED dies, respectively, or be blue, green,and red LED dies, respectively. Such an opto-electronic apparatus canalso be used, for example, as a full-color display panel or as awhite-light illumination panel.

In some embodiments, the opto-electronic device dies 1106 a, 1106 b, and1106 c are light-absorbing dies such as photodetector dies that absorblight of different wavelengths or different wavelength ranges. Forexample, the first opto-electronic device die 1106 a can be aphotodetector die detecting blue light, the second opto-electronicdevice die 1106 b can be a photodetector dies detecting green light, andthe third opto-electronic device die 1106 c can be a photodetector diedetecting red light. Such an opto-electronic apparatus can also be used,for example, as a full-color sensor used in a digital camera.

As shown in FIG. 11, the first opto-electronic device die 1106 aincludes a first active layer 1110 a associated with the firstwavelength or the first wavelength range. The second opto-electronicdevice die 1106 b includes a second active layer 1110 b associated withthe second wavelength or the second wavelength range, and formed over afirst dummy layer 1110 a′. The third opto-electronic device die 1106 cincludes a third active layer 1110 c associated with the thirdwavelength or the third wavelength range, and formed over a second dummylayer 1110 b′. The second dummy layer 1110 b′ is in turn formed over athird dummy layer 1110 a″. Consistent with the present disclosure, thefirst active layer 1110 a, the first dummy layer 1110 a′, and the thirddummy layer 1110 a″ have a similar material structure. Similarly, thesecond active layer 1110 b and the second dummy layer 1110 b′ have asimilar material structure.

As shown in FIG. 11, the first, second, and third opto-electronic devicedies 1106 a, 1106 b, and 1106 c are bonded to the driver circuit wafer102 through the bonding metal pads 108 of the bonding metal layer 107.In the embodiments described here in connection with FIG. 11 and belowin connection with FIGS. 12A-12K, the bonding metal layer 107 is alsoreferred to as “first bonding metal layer 107” and the bonding metalpads 108 are also referred to as “first bonding metal pads 108.” Theopto-electronic apparatus 1100 further includes a second bonding metallayer 1112 having a plurality of second bonding metal pads 1114 and athird bonding metal layer 1116 having a plurality of third bonding metalpads 1118 (one of which is shown in FIG. 11). The second active layer1110 b is bonded to the first dummy layer 1110 a′ through one of thesecond bonding metal pads 1114. The second dummy layer 1110 b′ is bondedto the third dummy layer 1110 a″ through another one of the secondbonding metal pads 1114. Further the third active layer 1110 c is bondedto the second dummy layer 1110 b′ through one of the third bonding metalpads 1118.

FIGS. 12A-12K schematically show an exemplary process for manufacturingthe opto-electronic apparatus 1100 consistent with embodiments of thepresent disclosure. In this exemplary process, the step for forming thefirst pre-bonding metal layer 202 over the driver circuit wafer 102 issimilar to that described above in connection with FIG. 2A. Therefore,this step is not illustrated again in FIGS. 12A-12K, and the descriptionthereof is omitted.

Referring to FIG. 12A, a second pre-bonding metal layer 1202 is formedover a first opto-electronic device wafer 1204. The firstopto-electronic device wafer 1204 includes a first opto-electronicdevice epi-structure layer 1206 epitaxially grown on a first growthsubstrate 1208. Next, as shown in FIG. 12B, the first opto-electronicdevice wafer 1204 is bonded to the driver circuit wafer 102, with thesecond pre-bonding metal layer 1202 and the first pre-bonding metallayer 202 being bonded together to form a first unpatterned bondingmetal layer 1210. Thereafter, as shown in FIG. 12C, the first growthsubstrate 1208 is removed to expose the first opto-electronic deviceepi-structure layer 1206.

Referring to FIG. 12D, a third pre-bonding metal layer 1212 is formedover the first opto-electronic device epi-structure layer 1206. Also, asshown in FIG. 12E, a fourth pre-bonding metal layer 1214 is formed overa second opto-electronic device wafer 1216, which includes a secondopto-electronic device epi-structure layer 1218 epitaxially grown on asecond growth substrate 1220. Next, as shown in FIG. 12F, the secondopto-electronic device wafer 1216 is bonded to the first opto-electronicdevice epi-structure layer 1206, with the fourth pre-bonding metal layer1214 and the third pre-bonding metal layer 1212 being bonded together toform a second unpatterned bonding metal layer 1222. Thereafter, as shownin FIG. 12G, the second growth substrate 1220 is removed to expose thesecond opto-electronic device epi-structure layer 1218.

Referring to FIG. 12H, a fifth pre-bonding metal layer 1224 is formedover the second opto-electronic device epi-structure layer 1218. Also,as shown in FIG. 12I, a sixth pre-bonding metal layer 1226 is formedover a third opto-electronic device wafer 1228, which includes a thirdopto-electronic device epi-structure layer 1230 epitaxially grown on athird growth substrate 1232. Next, as shown in FIG. 12J, the thirdopto-electronic device wafer 1228 is bonded to the secondopto-electronic device epi-structure layer 1218, with the sixthpre-bonding metal layer 1226 and the fifth pre-bonding metal layer 1224being bonded together to form a third unpatterned bonding metal layer1234. Thereafter, as shown in FIG. 12K, the third growth substrate 1232is removed to expose the third opto-electronic device epi-structurelayer 1230.

After the third growth substrate 1232 is removed, the remaining partsconstitute another exemplary semiconductor apparatus 1200 consistentwith embodiments of the present disclosure. That is, the semiconductorapparatus 1200 is an intermediate product formed during the process offorming the semiconductor apparatus 1100. As shown in FIG. 12, thesemiconductor apparatus 1200 includes the driver circuit wafer 102having the plurality of driver circuits 104 arranged in an array, thefirst unpatterned bonding metal layer 1210 formed over the drivercircuit wafer 102, the first opto-electronic device epi-structure layer1206 formed over the first unpatterned bonding metal layer 1210, thesecond unpatterned bonding metal layer 1222 formed over the firstopto-electronic device epi-structure layer 1206, the secondopto-electronic device epi-structure layer 1218 formed over the secondunpatterned bonding metal layer 1222, the third unpatterned bondingmetal layer 1234 formed over the second opto-electronic deviceepi-structure layer 1218, and the third opto-electronic deviceepi-structure layer 1230 formed over the third unpatterned bonding metallayer 1234. In particular, like the semiconductor apparatus 1100, thesemiconductor apparatus 1200 does not include any growth substrate, andtherefore the third opto-electronic device epi-structure layer 1230 isexposed to the environment. Different from the semiconductor apparatus1100, the semiconductor apparatus 1200 has horizontally continuousfirst, second, and third unpatterned bonding metal layers 1210, 1222,and 1234, and horizontally continuous first, second, and thirdopto-electronic device epi-structure layers 1206, 1218, and 1230.

According to the present disclosure, after the first, second, and thirdopto-electronic device epi-structure layers 1206, 1218, and 1230 arebonded onto the driver circuit wafer 102, subsequent processes includingpatterning the opto-electronic device epi-structure layers 1206, 1218,and 1230, and the first, second, and third unpatterned bonding metallayers 1210, 1222, and 1234, are performed to form the opto-electronicapparatus 1110 shown in FIG. 11.

In the exemplary process described above in connection with FIGS.12A-12K, the first, second, and third opto-electronic deviceepi-structure layers 1206, 1218, and 1230 are bonded to the drivercircuit wafer 102 sequentially in that order. However, the process forbonding the first, second, and third opto-electronic deviceepi-structure layers 1206, 1218, and 1230 according to the presentdisclosure is not limited to that exemplary process. Two or more of theopto-electronic device epi-structure layers 1206, 1218, and 1230 can befirst bonded to each other and then bonded to the driver circuit wafer102. For example, in one exemplary process, the first opto-electronicdevice epi-structure layer 1206 is bonded to the driver circuit wafer102. The second and third opto-electronic device epi-structure layers1218 and 1230 are first bonded to each other, and then the bondedstructure of the second and third opto-electronic device epi-structurelayers 1218 and 1230 is bonded to the first opto-electronic deviceepi-structure layer 1206. In another exemplary process, the first andsecond opto-electronic device epi-structure layers 1206 and 1218 arefirst bonded to each other, and then the bonded structure of the firstand second opto-electronic device epi-structure layers 1206 and 1218 isbonded to the driver circuit wafer 102. The third opto-electronic deviceepi-structure layer 1230 is then bonded to the second opto-electronicdevice epi-structure layer 1218. In a further exemplary process, thefirst, second, and third opto-electronic device epi-structure layers1206, 1218, and 1230 are first bonded together, and then the bondedstructure of the first, second, and third opto-electronic deviceepi-structure layers 1206, 1218, and 1230 is bonded to the drivercircuit wafer 102.

In the exemplary process described above in connection with FIGS.12A-12K and the exemplary semiconductor apparatus 1200 shown in FIG.12K, the first, second, and third opto-electronic device epi-structurelayers 1206, 1218, and 1230 are bonded to each other or to the drivercircuit wafer 102 through an unpatterned bonding metal layer. However,similar to the exemplary process described in connection with FIGS.3A-3D and the exemplary semiconductor apparatus 300 shown in FIG. 3D,and the exemplary process described in connection with FIGS. 4A-5B andthe exemplary semiconductor apparatus 400 shown in FIG. 4B, one or moreof the unpatterned bonding metal layers 1210, 1222, and 1234 can bepatterned during the process of forming the semiconductor apparatus1200. Correspondingly, in the semiconductor apparatus 1200, one or moreof the unpatterned bonding metal layers 1210, 1222, and 1234 can bereplaced with patterned bonding metal layers including a plurality ofbonding metal pads.

FIG. 11 schematically shows an exemplary semiconductor apparatusincluding three different types of opto-electronic device diesassociated with three different wavelengths or wavelength ranges. Insome embodiments, a semiconductor apparatus according to the presentdisclosure can include two different types of opto-electronic devicedies associated with two different wavelengths or wavelength ranges, orcan include four or more different types of opto-electronic device diesassociated with four or more different wavelengths or wavelength ranges.Each of the opto-electronic device dies is bonded to the driver circuitwafer 102, and includes one or more active layers. For anopto-electronic device die having multiple active layers, neighboringactive layers are also bonded to each other through a bonding metal pad.

Similarly, FIG. 12K schematically shows an exemplary semiconductorapparatus including three opto-electronic device epi-structure layersassociated with three different wavelengths or wavelength ranges. Insome embodiments, a semiconductor apparatus according to the presentdisclosure can include two opto-electronic device epi-structure layersassociated with two different wavelengths or wavelength ranges, or caninclude four or more opto-electronic device epi-structure layersassociated with four or more different wavelengths or wavelength ranges.Each of the opto-electronic device epi-structure layers is either bondedto the driver circuit wafer 102 through a bonding metal layer or bondedto another opto-electronic device epi-structure layer through a bondingmetal layer.

It is noted that the drawings of the present disclosure merelyillustrate the schematic structures of exemplary semiconductor apparatusconsistent with the present disclosure, but may not illustrate theactual shape and/or dimensions of the components of the semiconductorapparatus. For example, in the drawings described above, side walls ofthe functional device dies, such as the functional device dies 106 shownin FIG. 1, are shown perpendicular to the surfaces of the functionaldevice dies 106 and the driver circuit wafer 102. However, depending onthe method for patterning the functional device epi-structure layer,such as the functional device epi-structure layer 208 shown in FIG. 2B,and whether the functional device epi-structure layer is patternedbefore or after being bonded to the driver circuit wafer 102, the sidewalls of the resulting functional device dies can be tapered. Thetapering can be in different directions and have different taperingangles. Also, to simplify and generalize the description, some detailsand components of the semiconductor apparatus are not shown in thedrawings described above, such as the detailed structure of the drivercircuits 104 and other auxiliary components.

FIGS. 13A and 13B are cross-sectional views schematically showingexemplary LED panels 1300A and 1300B, respectively. As shown in FIG.13A, the LED panel 1300A includes a single crystalline Si substrate 1302and a plurality of driver circuits 1304 fabricated at least partially inthe substrate 1302. Each of the driver circuits 1304 includes anMOS-based integrated circuit. Although one MOS structure 1306 for eachdriver circuit 1304 is shown in FIG. 13A, it is to be understood thatthe driver circuit 1304 can have more than one MOS structure. The MOSstructure 1306 includes a first source/drain region 1306-1, a secondsource/drain region 1306-2, and a channel region 1306-3 formed betweenthe first and second source/drain regions 1306-1 and 1306-2. The MOSstructure 1306 further includes a gate 1306-4 and a gate dielectriclayer 1306-5 formed between the gate 1306-4 and the channel region1306-3. First and second source/drain contacts 1306-6 and 1306-7 areformed to be electrically coupled to the first and second source/drainregions 1306-1 and 1306-2, respectively, for electrically coupling thefirst and second source/drain regions 1306-1 and 1306-2 to otherportions of the LED panel 1300A.

As shown in FIG. 13A, the LED panel 1300A further includes an interlayerinsulation layer 1308 formed over the substrate 1302. In someembodiments, as shown in FIG. 13A, the interlayer insulation layer 1308includes a first sub-layer 1308-1 and a second sub-layer 1308-2. Adriver output electrode 1310 is formed in the second sub-layer 1308-2,and is electrically coupled to the second source/drain contact 1306-7through a plug portion 1312 formed in and through the first sub-layer1308-1.

The LED panel 1300A further includes a plurality of bonding metal pads1314, each of which is formed over one of the driver circuits 1304. AnLED die 1316 is formed over each of the bonding metal pads 1314.

As shown in FIG. 13A, side walls of the LED die 1316 are tapered in amanner such that the upper surface of the LED die 1316 is smaller thanthe lower surface of the LED die 1316. A sidewall passivation layer 1318is formed on the side walls of the LED die 1316. Consistent with thepresent disclosure, the LED panel 1300A can be formed, for example, bythe exemplary process described above in connection with FIGS. 3A-3E.

Referring to FIG. 13B, the LED panel 1300B is similar to the LED panel1300A, except that the LED panel 1300B includes LED dies 1320 havingside walls tapered in a different manner such that the upper surface ofeach of the LED dies 1320 is larger than the lower surface of that LEDdie 1320. Consistent with the present disclosure, the LED panel 1300Bcan be formed, for example, by the exemplary process described above inconnection with FIGS. 4A-4C or the exemplary process described above inconnection with FIGS. 5A and 5B.

It is noted that in the exemplary processes described above inconnection with the drawings of the present disclosure, the steps arenot necessarily performed in the sequence as they are arranged in thedrawings, but can be in a different order. For example, the step offorming the first pre-bonding metal layer 202 shown in FIG. 2A can beperformed before or after the step of forming the second pre-bondingmetal layer 204 shown in FIG. 2B. As another example, the step ofpatterning the first pre-bonding metal layer 202 to form the firstpre-bonding metal pads 302 shown in FIG. 3A can be performed before orafter the step of forming the second pre-bonding metal layer 204 shownin FIG. 2B, and can also be performed before or after the step ofpatterning the second pre-bonding metal layer 204 to form the secondpre-bonding metal pads 304 shown in FIG. 3B.

As discussed above, an LED panel consistent with the present disclosurecan be used as an imager device in an LED projector. As an example, FIG.14 schematically shows an exemplary mono-color LED projector 1400consistent with the present disclosure. The LED projector 1400 includesan LED display panel 1402 and a projection lens or lens set 1404. Lightemitted by the LED display panel 1402 is collected by the projectionlens or lens set 1404 and projected onto, for example, a screen (notshown).

As shown in FIG. 14, the LED display panel 1402 includes an LED panel1406 and a micro lens array 1408. The LED panel 1406 can be any LEDpanel consistent with the present disclosure, such as theabove-described LED panel 1300A or 1300B, and includes a plurality ofLED dies 1410. The micro lens array 1408 includes a plurality of microlenses 1412. Each of the micro lenses 1412 corresponds to one LED die1410, and is formed over the corresponding LED die 1410. Light emittedby an LED die 1410 is first converged by a corresponding micro lens 1412and then projected onto the projection lens 1404. As a result, thedivergence angle of the light emitted by the LED die 1410 is reduced bythe corresponding micro lens 1412.

Similarly, FIG. 15 schematically shows an exemplary full-color LEDprojector 1500 consistent with the present disclosure. The LED projector1500 includes an imaging unit 1502 and a projection lens or lens set1504. Similar to the LED projector 1400, in the LED projector 1500,light emitted by the imaging unit 1502 is collected by the projectionlens or lens set 1504 and projected onto, for example, a screen (notshown).

As shown in FIG. 15, the imaging unit 1502 includes LED display panels1506 and a beam combiner 1508. The LED display panels 1506 emit light ofdifferent colors, which are combined in the beam combiner 1508 and thenprojected to the projection lens 1504. Each of the LED display panels1506 includes an LED panel 1510 and a micro lens array 1512. Similar tothe LED panel 1406, the LED panel 1510 can be any LED panel consistentwith the present disclosure, such as the above-described LED panel 1300Aor 1300B, and includes a plurality of LED dies 1514. Further, similar tothe micro lens array 1408, the micro lens array 1512 includes aplurality of micro lenses 1516. Each of the micro lenses 1516corresponds to one LED die 1514, and is formed over the correspondingLED die 1514. Light emitted by an LED die 1514 is first converged by acorresponding micro lens 1516 and then projected into the beam combiner1508. As a result, the divergence angle of the light emitted by the LEDdie 1514 is reduced by the corresponding micro lens 1516.

FIG. 16 is a cross-sectional view schematically showing an exemplary LEDdisplay panel 1600 consistent with the present disclosure. The LEDdisplay panel 1600 includes an LED panel 1602, an optical spacer 1604formed over the LED panel 1602, and a micro lens array 1606 formed overthe optical spacer 1604.

The LED panel 1602 includes a driver circuit wafer 1608, a bonding metallayer 1610 formed over the driver circuit wafer 1608, and an LED array1612 formed over the bonding metal layer 1610. The driver circuit wafer1608 includes a substrate 1608-2 and a plurality of driver circuits1608-4, also referred to as “pixel driver circuits,” at least partiallyformed in the substrate 1608-2. The driver circuits 1608-4 form a drivercircuit array. The driver circuit wafer 1608 is similar to the exemplarydriver circuit wafers described above, such as the driver circuit wafer102 described above with reference to FIG. 1, and thus its detaileddescription is omitted here. Further, the substrate 1608-2 and thedriver circuits 1608-4 are similar to the exemplary substrates anddriver circuits described above, such as the substrate 1302 and thedriver circuits 1304 described above, respectively, with reference toFIGS. 13A and 13B, and thus their detailed description is omitted here.

The bonding metal layer 1610 includes a plurality of bonding metal pads1610-2. The bonding metal pads 1610-2 are similar to the exemplarybonding metal pads described above, such as the bonding metal pads 108described above with reference to FIG. 1, or the bonding metal pads 1314described above with reference to FIGS. 13A and 13B, and thus theirdetailed description is omitted here.

The LED array 1612 includes a plurality of LED dies 1612-2 arranged in amatrix, such as a triangular matrix, a square matrix, a rectangularmatrix, or a hexagonal matrix. The LED dies 1612-2 are similar to theexemplary LED dies described above, such as the LED dies 1006 describedabove with reference to FIG. 10, the LED dies 1106 described above withreference to FIG. 11, the LED dies 1316 described above with referenceto FIG. 13A, or the LED dies 1320 described above with reference to FIG.13B, and thus their detailed description is omitted here. Similar to theLED dies described above, each of the LED dies 1612-2 is bonded with acorresponding driver circuit 1608-4 by one corresponding bonding metalpad 1610-2. In some embodiments, the LED dies 1612-2 are identical orsimilar to each other and emit light of the same or similar color. Insome embodiments, the LED array 1612 includes different types of LEDdies, which can emit light of different colors.

In some embodiments, as shown in FIG. 16, the LED panel 1602 furtherincludes an insulation layer 1614 formed over the driver circuit wafer1608, the bonding metal layer 1610, and the LED array 1612. Theinsulation layer 1614 is also formed between the bonding metal pads1610-2 and between the LED dies 1612-2, to provide electrical isolationbetween neighboring bonding metal pads 1610-2 and between neighboringLED dies 1612-2. The insulation layer 1614 is configured not to blocklight emitted by the LED dies 1612-2. In some embodiments, the isolationlayer 1614 also provides optical isolation between neighboring LED dies1612-2.

The LED panel 1602 also includes a plurality of metal electrodes 1616and a common ground 1618. Each of the metal electrodes 1616 couples acorresponding LED die 1612-2 to the common ground 1618.

As shown in FIG. 16, the micro lens array 1606 includes a plurality ofmicro lenses 1606-2. Each of the micro lenses 1606-2 corresponds to andis formed over one of the LED dies 1612-2. Therefore, similar to the LEDdies 1612-2, the micro lenses 1606-2 can also be arranged in atriangular matrix or a square matrix. The optical spacer 1604 separatesthe micro lens array 1606 from the LED panel 1602, and provides anoptical path between each of the LED dies 1612-2 and a correspondingmicro lens 1606-2.

As shown in FIG. 16, a driver circuit 1608-4, a bonding metal pad 1610-2over the driver circuit 1608-4, an LED die 1612-2 over the bonding metalpad 1610-2, and a micro lens 1602-2 over the LED die 1612-2 form a pixel1620 of the LED display panel 1600. Consistent with the presentdisclosure, one pixel 1620 only includes one driver circuit 1608-4, onebonding metal pad 1610-2, one LED die 1612-2, and one micro lens 1606-2.That is, the driver circuits 1608-4, the bonding metal pads 1610-2, theLED dies 1612-2, and the micro lens 1606-2 have a one-to-onecorresponding relationship with respect to each other.

As shown in FIG. 16, the light emitted by the LED die 1612-2 (light fromone LED die 1612-2 is illustrated in FIG. 16) is more converged afterpassing through the corresponding micro lens 1606-2. That is, thedivergence angle of the light emitted by the LED die 1612-2 is reduced.For example, the divergence angle of the light exiting the micro lenses1606-2 can be reduced to about 40° from a divergence angle of about 110°when emitted by the LED dies 1612-2.

In some embodiments, the thickness of the optical spacer 1604, and hencethe distance between the LED dies 1612-2 and the micro lenses 1606-2,can be varied to achieve different divergence angle reduction results.Further, the distance between the LED dies 1612-2 and the micro lenses1606-2 also affects how much light can be collected by each micro lens1606-2 and how much the divergence angle can be reduced. With a smallerdistance between the LED dies 1612-2 and the micro lenses 1606-2, morelight from the LED dies 1612-2 may be collected by corresponding microlenses 1606-2, but the light is less converged. On the other hand, whenthe distance between the LED dies 1612-2 and the micro lenses 1606-2 islarger, less light may be collected by corresponding micro lenses 1606-2but the collected light is more converged, i.e., the light exiting themicro lenses 1606-2 has a smaller divergence angle. In some embodiments,the optical thickness of the optical spacer 1604, i.e., the product ofthe actual geometrical thickness of the optical spacer 1604 and therefractive index of the optical spacer 1604, can be chosen to be about 0times to about twice the focal length of the micro lenses 1606-2.

In FIG. 16, for illustrative purposes, the optical spacer 1604 and themicro lens array 1606 are assumed to be made of the same material, or bemade of materials having the same or similar refractive index, and thusno refraction occurs at the boundary between the optical spacer 1604 andthe micro lens array 1606. In some embodiments, the optical spacer 1604and the micro lens array 1606 can be made of different materials havingdifferent refractive indices. In such embodiments, refraction can occurat the boundary between the optical spacer 1604 and the micro lens array1606. For example, the micro lens array 1606 can be made of a materialhaving a refractive index larger than that of the material of theoptical spacer 1604. In this scenario, the light emitted by the LED dies1612-2 can be further converged.

Consistent with the present disclosure, the optical spacer 1604 can bemade of, for example, glass, semiconductor, or air. The micro lens array1606 can be made of, for example, glass or semiconductor. In someembodiments, the optical spacer 1604 and the micro lens array 1606 aremade from a same piece of material. That is, an original piece ofmaterial is processed such that a portion of the piece of material formsthe optical spacer 1604 and another portion of the piece of materialforms the micro lens array 1606. In FIG. 16 and other figures to bedescribed below, a line is drawn between the optical spacer 1604 and themicro lens array 1606. This line is merely for illustrative purposes toshow the boundary between the optical spacer 1604 and the micro lensarray 1606, but does not necessarily indicate an actual physicalinterface between the optical spacer 1604 and the micro lens array 1606.Depending on the materials and manufacturing processes for the opticalspacer 1604 and the micro lens array 1606, there may or may not be anactual physical interface between the optical spacer 1604 and the microlens array 1606. The optical spacer 1604 and the micro lens array 1606can be made of materials that are optically transparent orsemi-transparent to the light emitted by the LED dies 1612-2, such aspolymers, dielectrics, and semiconductors. In some embodiments, theoptical spacer 1604 can include an air gap. Consistent with the presentdisclosure, the materials for the optical spacer 1604 and the micro lensarray 1606 can also be varied to achieve different divergence anglereduction results.

The shape of the micro lenses 1606-2 can be chosen to achieve differentdivergence angle reduction results. For example, the micro lenses 1606-2can be spherical lenses, aspherical lenses, or Fresnel lenses. Thebottom of each micro lens 1606-2 can have, for example, a circularshape, a square shape, a rectangular shape, a triangular shape, or ahexagonal shape.

Further, the size of a micro lens 1606-2 as relative to the size of thecorresponding LED die 1612-2 can be adjusted to achieve differentdivergence angle reduction results. Consistent with the presentdisclosure, the lateral size, such as the diameter, of the micro lens1606-2 is larger than the lateral size of the corresponding LED die1612-2. Here, “lateral” refers to the horizontal direction as seen inthe drawings and the lateral size of the bottom of the micro lens 1606-2is used as the lateral size of the micro lens 1606-2. In someembodiments, the lateral size of the micro lens 1606-2 equals or islarger than about twice of the lateral size of the corresponding LED die1606-2.

Moreover, the material and the shape of the micro lenses 1606-2 can alsoaffect the numerical aperture of the micro lenses 1606-2, and thusaffect the capability of the micro lenses 1606-2 to reduce thedivergence angle. A micro lens 1606-2 having a larger curvature and/or ahigher refractive index can better reduce the divergence angle.

FIGS. 17A-17D show an exemplary process for manufacturing the LEDdisplay panel 1600 consistent with the present disclosure. As shown inFIG. 17A, the LED panel 1602 is provided. The LED panel 1602 can bemanufactured using a suitable method consistent with the presentdisclosure, such as one of the exemplary methods described above. Forexample, the LED panel 1602 can be manufactured using the processdescribed above with reference to FIGS. 2A-2E.

As shown in FIG. 17B, the optical spacer 1604 is formed over the LEDpanel 1602. In some embodiments, the optical spacer 1604 can be formedby applying a transparent material over the LED panel 1602. Thetransparent material can be, for example, a polymer material, adielectric material, such as silicon oxide, or a semiconductor material,such as gallium nitride. The transparent material can be applied by, forexample, a chemical-vapor deposition process, a physical-vapordeposition process, or a spin-on process. In some embodiments, theas-deposited transparent material can be flattened by, for example,polishing. In some embodiments, instead of applying a transparentmaterial over the LED panel 1602, which is then processed to form theoptical spacer 1604, the optical spacer 1604 can be pre-formedseparately and then bonded onto the LED panel 1602.

Referring to FIG. 17C, after the optical spacer 1604 is formed, apolymer layer 1702 is formed over the optical spacer 1604 by, forexample, a spin-on process. Then, as shown in FIG. 17D, the polymerlayer 1702 is patterned using, for example, a photolithography process,to form a patterned polymer layer 1704. The patterned polymer layer 1704includes a plurality of polymer units 1704-2 arranged in an array, eachof which corresponds to and is formed over one of the LED dies 1612-2.In some embodiments, the lateral size of the polymer units 1704-2 can becontrolled to control the lateral size of the micro lenses 1606-2. Insome embodiments, the thickness of the patterned polymer layer 1704 canbe controlled to control the shape, for example, the curvature of themicro lenses 1606-2.

In some embodiments, the polymer layer 1702 can be made ofphoto-sensitive polymer, such that the polymer layer 1702 can bepatterned by directly performing a photolithography process on thepolymer layer 1702. In some embodiments, the polymer layer 1702 is madeof non-photo-sensitive polymer. In such embodiments, a photoresist layer(not shown) can be formed over the polymer layer 1702, which ispatterned to a desired shape with a desired size. The polymer layer 1702is then etched using the patterned photoresist layer as a mask to formthe patterned polymer layer 1704.

After the polymer layer 1702 is patterned, a high-temperature reflowprocess is performed to convert the polymer units 1704-2 into the microlens 1606-2, forming the LED display panel 1600 shown in FIG. 16. Thereflow process can be performed at a temperature above the melting pointor the glass transition point of the polymer. The temperature and timeperiod of the reflow process can be controlled to control the sizeand/or shape of the micro lenses 1606-2. For example, the reflow processcan be performed at a temperature of about 180° C. for a period of about10 minutes.

Other processes can also be used to form the micro lenses 1606-2 out ofthe polymer layer 1702. FIGS. 18, 19, and 20 show other exemplaryprocesses for manufacturing the LED display panel 1600 consistent withthe present disclosure. In these exemplary processes, the steps offorming the LED panel 1602, the optical spacer 1604, and the polymerlayer 1702 are similar to those described above with reference to FIGS.17A-17C. Therefore, these steps are not illustrated again and theirdescription is omitted here.

In the exemplary process shown in FIG. 18, the polymer layer 1702 ismade of photo-sensitive polymer and is directly exposed using agrayscale mask 1802. The grayscale mask 1802 has a grayscale patterncorresponding to the micro lenses 1606-2 to be formed. As shown in FIG.18, due to the grayscale pattern, different regions of the polymer layer1702 receives different amounts of exposure. Therefore, during thesubsequent developing process, different amounts of polymer material areremoved from different regions of the polymer layer 1702, forming themicro lenses 1606-2 having curved surfaces, as shown in FIG. 16. In theprocess shown in FIG. 18, the exposure dose and time period, as well asthe pattern in the grayscale mask 1802, can be controlled to control thesize and shape of the micro lenses 1606-2.

In the exemplary process shown in FIG. 19, the polymer layer 1702 can bemade of non-photo-sensitive polymer. In this process, a pre-fabricatedmold/imprinting stamp 1902 is pressed into the polymer layer 1702 toconvert at least a portion of the polymer layer 1702 into the microlenses 1606-2. In some embodiments, during the imprinting process shownin FIG. 19, the polymer layer 1702 can be heated to soften or melt thepolymer layer 1702. The pre-fabricated mold/imprinting stamp 1902 can bedesigned as desired so that the as-formed micro lenses 1606-2 can havethe desired shape and size.

In the exemplary process shown in FIG. 20, the polymer layer 1702 can bemade of non-photo-sensitive polymer. As shown in FIG. 20, a patternedphotoresist layer 2002 is formed over the polymer layer 1702. Thepatterned photoresist layer 2002 includes a plurality of dummy units2002-2 each having a size and a shape mimicking those of thecorresponding micro lens 1606-2 to be formed. In some embodiments, thepatterned photoresist layer 2002 is formed by applying a photoresistlayer over the polymer layer 1702, patterning the photoresist layer toform photoresist units, and conducting a high-temperature reflow processto transform the photoresist units to the dummy units 2002-2. In someembodiments, the photoresist layer can be directly subject to aphotolithography process using a grayscale mask, such as the grayscalemask 1802 shown in FIG. 18, to form the patterned photoresist layer2002.

As shown in FIG. 20, a plasma or ion etching is performed on thepatterned photoresist layer 2002 and the polymer layer 1702. Sincedifferent regions in the patterned photoresist layer 2002 have differentthicknesses, different amounts of polymer material are etched fromcorresponding regions of the polymer layer 1702. As a result, the shapeand size of the dummy units 2002-2 is “transferred” to the polymer layer1702, forming the micro lenses 1606-2.

When the process of FIG. 20 is employed, the layer being etched to formthe micro lenses 1606-2 does not need to be made of polymer. Thus,instead of the polymer layer 1702, another processing layer made of, forexample, a dielectric material or a semiconductor material, can beformed over the optical layer 1604 and be processed to form the microlenses 1606-2.

In the exemplary processes described above with reference to FIGS. 19and 20, the optical layer 1604 and the polymer layer 1702 are formedseparately. Alternatively, in some embodiments, a processing layer canbe formed over the LED panel 1602 instead of separate optical layer 1604and polymer layer 1702. An upper portion of the processing layer can beprocessed using a process similar to one of the exemplary processesdescribed above with reference to FIGS. 19 and 20, to form the microlens array 1606. The remaining lower portion of the processing layerfunctions as the optical layer 1604. When the process of FIG. 19 isemployed, the processing layer can be entirely made of polymer. When theprocess of FIG. 20 is employed, the processing layer can be entirelymade of polymer, dielectric, or semiconductor.

FIG. 21 is a cross-sectional view schematically showing anotherexemplary LED display panel 2100 consistent with the present disclosure.The LED display panel 2100 includes the LED panel 1602, a bondingpolymer layer 2102 formed over the LED panel 1602, and a pre-fabricatedmicro lens assembly 2104 bonded to the LED panel 1602 through thebonding polymer layer 2102. As shown in FIG. 21, a portion of the microlens assembly 2104 is pre-fabricated to a plurality of curvedprotrusions 2104-2. The plurality of curved protrusions 2104-2constitute the micro lenses 1606-2 and form the micro lens array 1606.The remaining part of the micro lens assembly 2104, also referred toherein as a “base portion 2104-4,” and the bonding polymer layer 2102together constitute the optical spacer 1604. The micro lens assembly2104 can be fabricated using, for example, one of the above-describedprocesses for forming micro lenses.

In the LED display panel 2100, the micro lens assembly 2104 is bonded tothe LED panel 1602 through the bonding polymer layer 2102. In someembodiments, the micro lens assembly 2104 and the LED panel 1602 can beassembled together by other means. FIGS. 22A and 22B are cross-sectionalviews schematically showing other exemplary LED display panels 2200A and2200B consistent with the present disclosure. The LED display panels2200A and 2200B include the LED panel 1602, the micro lens assembly2104, and a mechanical fixture 2202 holding the LED panel 1602 and themicro lens assembly 2104. In particular, the mechanical fixture 2202includes a first clamping mechanism 2202-2 and a second clampingmechanism 2202-4. The first clamping mechanism is configured to receivea portion of the LED panel 1602 so as to hold the LED panel 1602. Thesecond clamping mechanism 2202-4 is configured to receive a portion ofthe micro lens assembly 2104, such as a portion of the base portion2104-4, so as to hold the micro lens assembly 2104. The first and secondclamping mechanisms 2202-2 and 2202-4 can be, for example, recesses inthe mechanical fixture 2202.

In the LED display panel 2200A, the protrusions 2104-2 of the micro lensassembly 2104 face the LED panel 1602. An air gap 2206 between the microlens assembly 2104 and the LED panel 1602 constitutes the optical spacer1604. In this case, since the flat base portion 2104-4 faces outwards,the protrusions 2104-2, i.e., the micro lenses 1606-2, can be protectedfrom damage by external forces. On the other hand, in the LED displaypanel 2200B, the protrusions 2104-2 of the micro lens assembly 2104 facetowards an opposite direction, i.e., the direction facing away from theLED panel 1602. In this case, the air gap 2206 and the base portion2104-2 together constitute the optical spacer 1604.

In the exemplary LED display panels described above, the optical spacerand the micro lens array are made separately from the LED panel 1602.Sometimes, LED dies in an LED panel can also be manufactured usingflip-chip technology. That is, semiconductor epitaxial layers are firstepitaxially grown on a growth substrate and fabricated to form LED dies.The resulting epitaxial wafer including the growth substrate and the LEDdies is flipped over and bonded to a driver circuit wafer throughbonding pads. Usually, the growth substrate is then thinned by, forexample, a polishing process. Consistent with the present disclosure, aportion of the growth substrate can be fabricated into micro lenses,such that no extra layers need to be formed.

FIG. 23 is a cross-sectional view schematically showing anotherexemplary LED display panel 2300 consistent with the present disclosure.In the LED display panel 2300, the LED dies, the optical spacer, and themicro lenses are formed from the same semiconductor epitaxial wafer.

As shown in FIG. 23, the LED display panel 2300 includes an LED panel2302, an optical spacer 2304 over the LED panel 2302, and a micro lensarray 2306 over the optical spacer 2304. The LED panel 2302 includes adriver circuit wafer 2308, a bonding metal layer 2310 formed over thedriver circuit wafer 2308, and an LED array 2312 formed over the bondingmetal layer 2310. The driver circuit wafer 2308 includes a plurality ofdriver circuits 2308-4. The driver circuit wafer 2308 and the drivercircuits 2308-4 are similar to the driver circuit wafer 1608 and thedriver circuits 1608-4 described above with reference to FIG. 16, andthus their detailed description is omitted here.

The LED array 2312 includes a plurality of flip-chip LED dies 2312-2.The bonding metal layer 2310 includes first bonding metal pads 2310-2and second bonding metal pads 2310-4. Each of the first bonding metalpads 2310-2 is electrically coupled to one electrode, such as thep-electrode, of the corresponding LED die 2312-2, and is alsoelectrically coupled to the corresponding driver circuit 2308-4.Similarly, each of the second bonding metal pads 2310-4 is electricallycoupled to another electrode, such as the n-electrode, of thecorresponding LED die 2312-2, and is coupled to a common ground 2318.

As shown in FIG. 23, the optical spacer 2304 includes a plurality ofspacer units 2304-2 separated and electrically isolated from each other.Each of the spacer units 2304-2 corresponds to one of the LED dies2312-2. Since the LED dies 2312-2 and the optical spacer 2304 are formedof the same semiconductor growth substrate, electrically isolating thespacer units 2304-2 ensures electrical isolation between the LED dies2312-2.

Further, the micro lens array 2306 includes a plurality of micro lenses2306-2. The micro lenses 2306-2 are similar to the micro lenses 1606-2in terms of size, shape, and configuration, but are made from the samesemiconductor epitaxial layer as the optical spacer units 2304-2 and theLED dies 2312-2. As shown in FIG. 23, the micro lenses 2306-2 are alsoseparated and electrically isolated from each other.

Specifically, to form the LED display panel 2300 having the micro lenses2306-2, an exemplary process described below can be used. First, asemiconductor epitaxial layer is grown on a semiconductor growthsubstrate. The semiconductor epitaxial layer can include a plurality ofepitaxial sub-layers according to the LED array 2312 to be formed. Thesemiconductor epitaxial layer is then processed to form the LED array2312, resulting in a semiconductor epitaxial wafer having the pluralityof LED dies 2312-2 formed on one side of the semiconductor epitaxiallayer, which in turn is formed on the semiconductor growth substrate.The semiconductor epitaxial wafer is then aligned and bonded onto thedriver circuit wafer 2308 such that each of the LED dies 2312-2 isbonded to one of the driver circuits 2308-4 of the driver circuit wafer2308. After bonding, the semiconductor growth substrate is removed,leaving the semiconductor epitaxial layer bonded to the driver circuitwafer 2308. The semiconductor growth substrate can be removed by, forexample, a laser lift-off process or an etching process, such as a wetetching process or a dry etching process. The back side of thesemiconductor epitaxial layer, i.e., the side opposite to the side onwhich the LED dies 2312-2 are formed, is processed using, for example,one of the above-described processes for forming micro lenses. In someembodiments, the semiconductor epitaxial layer is processed such thatthe micro lenses 2306-2 are separated and electrically isolated fromeach other. Further, a portion of the semiconductor epitaxial layerbetween the micro lens array 2306 and the LED array 2312 is processed toform the spacer units 2304-2 that are separated and electricallyisolated from each other by, for example, an etching process. In someembodiments, before the process for forming the micro lenses 2306-2 isconducted, the semiconductor epitaxial layer is thinned from the backside, for example, by a polishing process or an etching process.

In the exemplary LED display panel described above, one pixel of the LEDdisplay panel includes one LED die, i.e., each driver circuit controlsone LED die. In some embodiments, the LED display panel can have pixelseach including two or more LED dies, in which each driver circuitcontrols two or more LED dies.

FIG. 24A is a cross-sectional view of another exemplary LED displaypanel 2400A consistent with the present disclosure. The LED displaypanel 2400A is similar to the LED display panel 1600, except that in theLED display panel 2400A, each pixel 1620 includes two LED dies 1612-2(only one pixel is shown in FIG. 24A). The two LED dies 1612-2 in thesame pixel 1620 are coupled in parallel to each other and are coupled tothe same driver circuit 1608-4. In the LED display panel 2400A, the twoLED dies 1612-2 in the same pixel 1620 correspond to different microlenses 1606-2.

FIG. 24B is a cross-sectional view of another exemplary LED displaypanel 2400B consistent with the present disclosure. The LED displaypanel 2400B is similar to the LED display panel 2400A, except that inthe LED display panel 2400B, the two LED dies 1612-2 in the same pixel1620 share the same micro lens 1606-2. Although FIG. 24B shows two LEDdies 1612-2 sharing the same micro lens 1606-2, the disclosed device canalso be practiced with more than two LED dies sharing the same microlens. That is, according to the present disclosure, each micro lens cancorrespond to and be arranged over two or more LED dies.

In some embodiments, for example, as shown in FIGS. 16, 21, 22A, 22B,23, and 24A, each micro lens is aligned with one corresponding LED die,e.g., the center of the micro lens is approximately aligned with thecenter of the corresponding LED die. In some embodiments, for example,as shown in FIG. 24B, the micro lens does not align with individual LEDdies.

Other embodiments of the disclosure will be apparent to those skilled inthe art from consideration of the specification and practice of theinvention disclosed herein. It is intended that the specification andexamples be considered as exemplary only, with a true scope and spiritof the invention being indicated by the following claims.

What is claimed is:
 1. A light-emitting diode (LED) display panel,comprising: a substrate; a driver circuit array on the substrate andincluding a plurality of pixel driver circuits arranged in an array; anLED array including a plurality of LED dies each being coupled to one ofthe pixel driver circuits; an electrical coupling layer formed betweenthe driver circuit array and the LED array, the electrical couplinglayer including a plurality of layers stacked in a vertical direction; amicro lens array including a plurality of micro lenses eachcorresponding to and being arranged over at least one of the LED dies;an optical spacer formed between the LED array and the micro lens array;and a dielectric isolation layer arranged between the driver circuitarray and the LED array, the dielectric isolation layer including firstprotrusion structures and second protrusion structures surrounding eachof the first protrusion structures, wherein the optical spacer includesa polymer material, a dielectric material, a semiconductor material, oran air gap, the electrical coupling layer includes a plurality ofelectrical coupling pads arranged in an array and isolated from eachother, each of the pixel driver circuits corresponding to one of theelectrical coupling pads, each first protrusion structure is formedbetween one of the electrical coupling pads and one of the pixel drivercircuits, and has a through hole formed from an upper surface of thefirst protrusion structure to a lower surface of the first protrusionstructure, at least a portion of the electrical coupling pad beingarranged in the through hole, and each of the first protrusionstructures and the second protrusion structures surrounding the firstprotrusion structure define a continuous recess surrounding the firstprotrusion structure.
 2. The LED display panel of claim 1, wherein eachof the micro lenses is aligned with the corresponding one of the LEDdies.
 3. The LED display panel of claim 1, wherein the micro lens arrayis made of one of a polymer material, a dielectric material, or asemiconductor material.
 4. The LED display panel of claim 1, wherein themicro lenses are arranged in a triangular matrix, a square matrix, arectangular matrix, or a hexagonal matrix.
 5. The LED display panel ofclaim 1, wherein each of the micro lenses has a lateral size larger thana lateral size of the corresponding at least one of the LED dies.
 6. TheLED display panel of claim 1, wherein each of the micro lenses includesone of a spherical lens, an aspherical lens, or a Fresnel lens.
 7. TheLED display panel of claim 1, wherein a bottom of each of the microlenses has one of a circular shape, a square shape, a rectangular shape,a triangle shape, or a hexagonal shape.
 8. The LED display panel ofclaim 1, wherein the optical spacer and the micro lens array are formedof a same material.
 9. The LED display panel of claim 1, wherein eachpixel driver circuit is coupled to two or more LED dies.
 10. The LEDdisplay panel of claim 9, wherein the two or more LED dies coupled tothe same pixel driver circuit are coupled to each other in parallel. 11.The LED display panel of claim 1, wherein each of the micro lensescorresponds to and is arranged over two or more of the LED dies.
 12. TheLED display panel of claim 1, wherein: the micro lens array includes aprotrusion portion of a micro lens assembly, the optical spacer includesa base portion of the micro lens assembly and a bonding polymer layerbetween the micro lens assembly and the LED array, the micro lensassembly is made from a single piece of material separate from the LEDarray, and the micro lens assembly is bonded to the LED array throughthe bonding polymer layer.
 13. The LED display panel of claim 1, furthercomprising: a mechanical fixture holding the driver circuit wafer andthe micro lens array, wherein the optical spacer includes an air gap.14. The LED display panel of claim 13, wherein: the micro lens arrayincludes a protrusion portion of a micro lens assembly, and theprotrusion portion faces the LED array.
 15. The LED display panel ofclaim 13, wherein: the micro lens array includes a protrusion portion ofa micro lens assembly, the micro lens assembly further includes a baseportion supporting the protrusion portion, the protrusion portion facesopposite to the LED array, and the optical spacer further includes thebase portion.
 16. The LED display panel of claim 1, wherein the LEDarray, the optical spacer, and the micro lens array are made from a samesemiconductor epitaxial layer grown on a semiconductor growth substrate.17. The LED display of claim 16, wherein: the optical spacer includes aplurality of spacer units separated and electrically isolated from eachother, and each of the spacer units corresponds to and is formed overone of the LED dies.